Inductance element for power capacitor assembly

ABSTRACT

An inductive element is integrally configurable within a power capacitor assembly. The inductive element includes a plurality of electrically conductive sheets electrically connected in parallel, and which sheets are rolled and formed into a generally cylindrical body. A first electrode is in electrical contact with one end of the electrically conductive sheets, and a second electrode in electrical contact with the opposite end of said electrically conductive sheets.

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to power capacitor assemblies used in power transmission and distribution systems and, more particularly, to an inductance element for a power capacitor assembly.

[0002] Electrical utility networks supply power for both commercial and residential purposes. In typical power networks, transmission lines carry both real and reactive power. The reactive power usually energizes cables, switches large industrial gears, and energizes reactive loads (e.g. motors and transformer coils), whereas the real power carried by the distribution lines performs the work at the load connected to the line. Multiphase, alternating current (AC) electrical networks tend to undergo undesirable reactive power changes when subjected to the repeated connection and disconnection of large reactive loads onto and off of the distribution line. The reactive power changes that occur in the network generally result in low system efficiency and high-energy losses. More specifically, these energy losses occur, for example, when large inductive loads are connected to the distribution lines, thus producing in inordinate amount of lagging reactive current in the line. Accordingly, it is desirable to provide a compensation system to correct for such reactive power in the electrical line.

[0003] For this purpose, one compensation technique is to use a number of high voltage capacitor banks, each of which can be selectively connected or disconnected from the network depending on the particular need for correction. High voltage capacitor units typically have both very low equivalent series resistance and inductance values, with the inductance values typically being on the order of 1 microhenry (μH). A low series resistance is desirable in order to limit power losses, while a low inductance is sometimes desirable in applications where it is advantageous to transfer energy out of a capacitor very rapidly. However, such low inductance characteristics can result in high inrush current transients when the capacitor is energized, particularly when there are multiple capacitor banks at the same location. In turn, high inrush current transients impose severe duty on associated switching devices, fuses, and the capacitors themselves.

[0004] In order to control high current transients, it is known in the art to externally connect a bank of reactors, or coils, to power capacitor assemblies. These external reactors act a “current choke” which protect the capacitors and help to maintain rupture tolerance. However, the use of large external components, such as reactor banks, can contribute to increased costs and maintenance of the power network.

[0005] Integrated inductor-capacitor devices (also referred to as cap-reactors) are also known in the art. These devices may include a pair of conducting foil sheets separated by a thin layer of dielectric material. The foil sheets and dielectric material are then typically rolled together in a cylindrical fashion to form a capacitor, having connective terminals protruding from the cylinder. In order to provide this type of capacitor with an inductive function, one connective terminal is usually located at the “start end” of the length of the first conductive foil and another connective terminal at the “finish end” of the second conductive foil. Although this arrangement produces an increased inductance value for the device (on the order of 100-200 μH), it also results in a relatively high equivalent series resistance. The series resistance can be approximately 30 times that of the entire capacitor since the length of the conducting path may be 100 or more feet long, depending on the size of the capacitor. This high equivalent series resistance would result in high thermal losses in the capacitor and adversely impact the efficiency of the power system.

[0006] A need, therefore, exists for a power capacitor assembly that addresses the aforementioned drawbacks.

BRIEF SUMMARY OF THE INVENTION

[0007] The above discussed and other drawbacks and deficiencies are overcome or alleviated by an inductive element integrally configurable within a power capacitor assembly. In an exemplary embodiment of the invention, the inductive element includes a plurality of electrically conductive sheets electrically connected in parallel. The sheets are rolled and formed into a generally cylindrical body. A first electrode is in electrical contact with one end of the electrically conductive sheets, and a second electrode in electrical contact with the opposite end of the electrically conductive sheets.

[0008] In one embodiment, the plurality of electrically conductive sheets is comprised of aluminum foil. Further, a layer of dielectric film material is disposed on one side of the plurality of electrically conductive sheets. The dielectric film material is preferably comprised of polypropylene, and the first and second electrodes are comprised of tinned copper straps.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:

[0010]FIG. 1 is a perspective view of a cylindrically shaped inductive element of an embodiment of the invention, shown partially unwound to reveal the configuration of materials contained therein;

[0011]FIG. 2 is a perspective view of the inductive element depicted in FIG. 1, after being flattened during manufacture;

[0012]FIG. 3 is a top view of a power capacitor assembly, including the inductive element shown in FIG. 2; and

[0013]FIG. 4 is a schematic representation of the power capacitor assembly in FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

[0014] Referring to FIG. 1, an inductive element 10 includes a plurality of electrically conductive, metallic foil sheets 12 wound about a longitudinal axis to form a generally cylindrical body 14. Disposed on one side of the metallic sheets 12 are two layers 16 of a dielectric film material, preferably polypropylene, which have a width greater than that of the metallic foil sheets 12. The dielectric layers 16 are used to provide electrical insulation for voltage transients. A first electrode 18 is connected on one end 19 of the length of the metallic foil sheets 12 by an electrode pocket 20. A second electrode 22 is similarly connected to the opposite end (not shown) of the length of sheets 12. The first and second electrodes include longitudinal axes, which may be substantially parallel to the longitudinal axis of body 14.

[0015] In a preferred embodiment, metallic sheets 12 are comprised of aluminum foil, with each individual sheet being thicker than 0.2 mil. In addition, the first and second electrodes 18, 22 are preferably 1 inch wide, 20 mil thick tinned copper straps. Electrodes 18, 22 are desired to have increased current carrying capacity in comparison to connecting terminals used in power capacitors, which connecting terminals are typically only 0.5 inches wide by 3.5 mil thick.

[0016] After being spirally wound on a retractable arbor or similar machine, the cylindrical body 14 is then flattened into the shape shown in FIG. 2 and an insulation material 24 is inserted into a slot 26 formed by the flattening process. Body 14, once flattened, may be inserted into a housing, as described hereinafter.

[0017] It can readily be seen that the shape and design of the inductive element lends itself to integration with a wound foil capacitor assembly. An important difference, however, between a capacitor of the wound foil capacitor type and the present invention is that the metallic foil sheets 14 in inductive element 10 are not electrically isolated from one another by a dielectric material, but rather are electrically connected in parallel. As mentioned previously, a foil wound capacitor could be configured to have inductive properties by locating connecting terminals at opposite ends of the electrode sheets, but the resulting increased resistance leads to undesirable power losses.

[0018]FIG. 3 illustrates the inductive element 10 integrated with a bank 28 of similarly shaped power capacitors 30, disposed within a uniform housing 32 thereby defining a power capacitor assembly 34. As illustrated by the schematic in FIG. 4, the inductive element 10 is connected in series with three pairs of power capacitors 30, which pairs of power capacitors are individually connected in parallel. Thus configured, the inductive element 10 will serve to resist any transient inrush currents to the capacitor bank 28 associated with energization of the bank. It should be noted, however, that the specific number of capacitors 30 shown in FIGS. 3 and 4 are one embodiment of the invention and are not to be construed or interpreted in a limiting sense. For example, the inductive element 10 may be connected to a single capacitor 30 inside housing 32, or any number of capacitors 30 as the case may be.

[0019] By featuring a comparative shape, design and materials features, the inductive element can easily be incorporated or manufactured into a bank of wound foil capacitors, thereby eliminating the need for (or reducing the size of) a separate reactor component.

[0020] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. An inductive element integrally configurable within a power capacitor assembly, said inductive element comprising: a plurality of electrically conductive sheets electrically connected in parallel, said plurality of electrically conductive sheets rolled and formed into a generally cylindrical body; a first electrode in electrical contact with a first end of said electrically conductive sheets; and a second electrode in electrical contact with a second end of said electrically conductive sheets.
 2. The inductive element of claim 1, wherein said plurality of electrically conductive sheets is comprised of aluminum foil.
 3. The inductive element of claim 1, further comprising a layer of dielectric film material disposed on one side of said plurality of electrically conductive sheets.
 4. The inductive element of claim 3, wherein said dielectric film material is polypropylene.
 5. The inductive element of claim 1, wherein said first and second electrodes comprise tinned copper straps.
 6. A method of manufacturing an inductive element for use in a power capacitor assembly, comprising: connecting a plurality of electrically conductive sheets in parallel; electrically connecting a first electrode to a first end of said electrically conductive sheets; electrically connecting a second electrode to a second end of said electrically conductive sheets; winding said plurality of electrically conductive sheets into a generally cylindrical body; and flattening said cylindrical body.
 7. The method of claim 6, further comprising affixing a layer of dielectric film material to one side of said plurality of electrically conductive sheets prior to winding said plurality of electrically conductive sheets into a generally cylindrical body.
 8. The method of claim 7, further comprising inserting an insulating material into a slot formed within said cylindrical body.
 9. A power capacitor assembly, comprising: a housing; a power capacitor disposed within said housing; and an induction element serially connected with said power capacitor, said inductive element further comprising: a plurality of electrically conductive sheets electrically connected in parallel, said plurality of electrically conductive sheets rolled and formed into a generally cylindrical body; a first electrode in electrical contact with a first end of said electrically conductive sheets; and a second electrode in electrical contact with a second end of said electrically conductive sheets.
 10. The power capacitor assembly of claim 9, wherein said inductive element is disposed within said housing.
 11. The power capacitor assembly of claim 10, wherein said plurality of electrically conductive sheets is comprised of aluminum foil.
 12. The power capacitor assembly of claim 10, further comprising a layer of dielectric film material disposed on one side of said plurality of electrically conductive sheets.
 13. The power capacitor assembly of claim 12, wherein said dielectric film material is polypropylene.
 14. The power capacitor assembly of claim 9, wherein said first and second electrodes comprise tinned copper straps. 